Chemical milling, or industrial etching, is the manufacturing process of using baths of temperature-regulated etching chemicals to remove material to create an object with the desired shape. It is mostly used on metals, though its use with other materials is becoming increasingly important.
Other names for chemical milling, or industrial etching, include photo etching, chemical etching, photo chemical etching, and photochemical machining.
The process was developed from ancient armor-decorating and printing etching processes that were originally developed during the Renaissance as alternatives to hand engraving on metal with tools.
How Chemical Milling Works
The chemical milling process involves bathing the cutting areas of a metal part in a corrosive chemical, often an acid mixture, which is known as an etchant. This etching solution reacts with the area to be etched in the material, often aluminum or steel, and causes the solid material to dissolve.
During the chemical milling process, certain inert substances known as maskants are used to mask, or protect, the areas specific areas of the material not being milled. This aspect of the chemical milling process is similar to masking areas being painted.
The Purpose of Chemical Milling
Chemical milling is used in the aerospace industry to remove shallow layers of material from large aircraft components, extruded parts for airframes, and other components such as missile skin panels.
The primary purpose of the chemical milling process is to reduce the weight of fuselage skins and other parts, so as to improve the overall efficiency of the aircraft. In addition, it is a process that can be used to chemically corrode aircraft material to produce blind features like pockets and channels.
The Benefits of Chemical Milling
The chemical milling process can allow for complicated shaped patterns to be applied to material. Used mostly in the aerospace and aircraft industry, the process has several benefits and advantages.
Many aerospace components are chemically milled in specific areas to reduce weight while retaining the overall strength and function of the parts. Typical parts that are lightened include engine nacelles, cowlings, and fairings.
Other benefits of this method include:
- Lower tooling costs
- No burrs are produced.
- Thin sheets of metal can be processed without distortion.
- Brittle materials can be easily processed.
Your Source for Aerospace Metals Products
AAA Air Support is a manufacturer and stocking distributor of quality raw materials for the Aerospace Industry including roll form stringers and extruded parts, as well many other aluminum, steel and titanium aviation and aerospace products.
In addition, we provide a full range of precision machining services. Our state-of-the-art processes ensure consistent quality production.
Whether you need 100 feet of an aluminum extrusion product, a square foot of titanium, or just a few inches of stainless-steel tubing, AAA Air Support promises to always ship out your order quickly, correct, and efficiently.
Our primary goal is to provide your company with all the materials to complete that project, make the repair, and get that airplane back in the air in challenging AOG situations.
Welcome to including the AAA Air Support Family and thank you for choosing us. As we respectfully ask all our customers, “How may we be of service?”
